Impact Tool

ABSTRACT

A tool comprising a super hard material is bonded to a cemented metal carbide substrate at a non-planar interface. A cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. The carbide bolster is secured against an outer surface of a drum through a press fit.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 12/021,019 filed on Jan. 28, 2008 which was a continuation-in-part of U.S. patent application Ser. No. 11/971,965 which is a continuation of U.S. patent application Ser. No. 11/947,644, which was a continuation-in-part of U.S. patent application Ser. No. 11/844,586. U.S. patent application Ser. No. 11/844,586 is a continuation-in-part of U.S. patent application Ser. No. 11/829,761. U.S. patent application Ser. No. 11/829,761 is a continuation-in-part of U.S. patent application Ser. No. 11/773,271. U.S. patent application Ser. No. 11/773,271 is a continuation in-part of U.S. patent application Ser. No. 11/766,903. U.S. patent application Ser. No. 11/766,903 is a continuation of U.S. patent application Ser. No. 11/766,865. U.S. patent application Ser. No. 11/766,865 is a continuation in-part of U.S. patent application Ser. No. 11/742,304. U.S. patent application Ser. No. 11/742,304 is a continuation of U.S. patent application Ser. No. 11/742,261. U.S. patent application Ser. No. 11/742,261 is a continuation in-part of U.S. patent application Ser. No. 11/464,008. U.S. patent application Ser. No. 11/464,008 is a continuation in-part of U.S. patent application Ser. No. 11/463,998. U.S. patent application Ser. No. 11/463,998 is a continuation-in-part of U.S. patent application Ser. No. 11/463,990. U.S. patent application Ser. No. 11/463,990 is a continuation in-part of U.S. patent application Ser. No. 11/463,975. U.S. patent application Ser. No. 11/463,975 is a continuation in-part of U.S. patent application Ser. No. 11/463,962. U.S. patent application Ser. No. 11/463,962 is a continuation-in-part of U.S. patent application Ser. No. 11/463,953. The present application is also a continuation-in-part of U.S. patent application Ser. No. 11/695,672. U.S. patent application Ser. No. 11/695,672 is a continuation-in-part of U.S. patent application Ser. No. 11/686,831. All of these applications are herein incorporated by reference for all that they contain.

BACKGROUND OF THE INVENTION

Formation degradation, such as asphalt milling, mining, or excavating, may result in wear on attack tools. Consequently, many efforts have been made to extend the life of these tools.

U.S. Pat. No. 3,830,321 to McKenry et al., which is herein incorporated by reference for all that it contains, discloses an excavating tool and a bit for use therewith in which the bit is of small dimensions and is mounted in a block in which the bit is rotatable and which block is configured in such a manner that it can be welded to various types of holders so that a plurality of blocks and bits mounted on a holder make an excavating tool of selected style and size.

U.S. Pat. No. 6,102,486 to Briese, which is herein incorporated by reference for all that it contains, discloses a frustum cutting insert having a cutting end and a shank end and the cutting end having a cutting edge and inner walls defining a conical tapered surface. First walls in the insert define a cavity at the inner end of the inner walls and second walls define a plurality of apertures extending from the cavity to regions external the cutting insert to define a powder flow passage from regions adjacent the cutting edge, past the inner walls, through the cavity and through the apertures.

U.S. Pat. No. 4,944,559 to Sionnet et al., which is herein incorporated by reference for all that it contains, discloses a body of a tool consisting of a single-piece steel component. The housing for the composite abrasive component is provided in this steel component. The working surface of the body has, at least in its component-holder part, and angle at the lower vertex of at least 20% with respect to the angle at the vertex of the corresponding part of a metallic carbide tool for working the same rock. The surface of the component holder is at least partially covered by an erosion layer of hard material.

U.S. Pat. No. 5,873,423 to Briese, which is herein incorporated by reference for all that it contains, discloses a frustum cutting bit arrangement, including a shank portion for mounting in, and to be retained by, a rotary cutting tool body, the shank portion having an axis, an inner axial end, and an outer axial end. A head portion has an axis coincident with the shank portion axis, a front axial end, and a rear axial end, the rear end coupled to the shank portion outer end, and the front end having a conical cavity therein diminishing in diameter from the front end toward the rear end. A frustum cutting insert has an axis coincident with the head portion axis, a forward axial end, a back axial end, and an outer conical surface diminishing in diameter from the forward end toward the back end, the conical cavity in a taper lock. In variations of the basic invention, the head portion may be rotatable with respect to the shank portion, the frustum cutting insert may comprise a rotating cutter therein, and combinations of such features may be provided for different applications.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a tool comprising a super hard material is bonded to a cemented metal carbide substrate at a non-planar interface. A cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. The carbide bolster is secured against an outer surface of a drum through a press fit.

The carbide substrate at the interface may comprise a tapered surface starting from a cylindrical rim of the substrate and ending at an elevated flatted central region formed in the substrate. The flatted region may comprise a diameter of 0.125 to 0.250 inches. The bolster may comprise a stem with a diameter of 0.250 to 1.00 inches. The stem may comprise a length of 35 to 100 percent of the length of the bolster. The drum may comprise a lug adapted to attach to the bolster. The lug may be threadedly attached to the drum and the carbide bolster. The lug may be press-fit into the carbide bolster. The lug may comprise a hydraulic pump adapted to move the lug and lock the carbide bolster against the drum. The carbide bolster may comprise a base end with a complimentary surface to that of the outer surface of the drum. The carbide bolster may be interlocked together. The carbide bolster may be interlocked through at least one flat. The carbide bolster may also comprise a stem that is adapted to be press-fit into the drum. The carbide bolster may comprise at least one bore opposite the front end. The bore may also be tapered. The super hard material may comprise a substantially conical surface with a side which forms a 35 to 55 degree angle with a central axis of the impact tool. The impact tool may be attached to a milling machine, a mining machine, a trenching machine, or a combination thereof.

In another aspect of the invention a high-impact resistant tool comprises a super hard material bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. The metal carbide bolster comprises a locking mechanism adapted to attach to a drum.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality of tools.

FIG. 1 a is cross-sectional diagram of an embodiment of a tool.

FIG. 1 b is another cross-sectional diagram of an embodiment of a tool.

FIG. 1 c is another cross-sectional diagram of an embodiment of a tool.

FIG. 1 d is another cross-sectional diagram of an embodiment of a tool.

FIG. 2 is another cross-sectional diagram of an embodiment of a plurality of tools disposed on a drum.

FIG. 3 is another cross-sectional diagram of an embodiment of a plurality of tools disposed on a drum.

FIG. 4 is a top perspective diagram of an embodiment of a plurality of tools.

FIG. 5 is another top perspective diagram of an embodiment of a plurality of tools.

FIG. 6 is another top perspective diagram of an embodiment of a plurality of tools.

FIG. 7 is a cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 8 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 9 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 10 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 11 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 12 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 13 is another cross-sectional diagram of an embodiment of a tool.

FIG. 14 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 15 is another cross-sectional diagram of an embodiment of a tool disposed on a surface.

FIG. 16 is another cross-sectional diagram of an embodiment of a tool disposed on a roller.

FIG. 17 is another cross-sectional diagram of another embodiment of a tool disposed on a roller.

FIG. 18 is another cross-sectional diagram of an embodiment of a tool.

FIG. 19 is another cross-sectional diagram of an embodiment of a tool disposed on a degradation machine.

FIG. 20 is another cross-sectional diagram of an embodiment of a tool disposed on a rotary device.

FIG. 21 is a cross-sectional diagram of an embodiment of a tool disposed on a percussion bit.

FIG. 22 is another cross-sectional diagram of an embodiment of a tool disposed on a percussion bit.

FIG. 23 is another cross-sectional diagram of a plurality of tools.

FIG. 24 is another cross-sectional diagram of a plurality of tools.

FIG. 25 is another cross-sectional diagram of a tool.

FIG. 26 is another cross-sectional diagram of a plurality of tools.

FIG. 27 is another cross-sectional diagram of a plurality of tools.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality of tools 101 attached to a driving mechanism, such as rotating drum 103, connected to the underside of a pavement recycling machine 100. The recycling machine 100 may be a cold planer used to degrade man-made formations such as a paved surface 104 prior to the placement of a new layer of pavement. Impact tools 101 may be attached to the driving mechanism bringing the impact tools 101 into engagement with the formation 104.

FIG. 1 a is a cross-sectional diagram of an embodiment of a tool 101. The tool 101 may comprise a super hard material 202 bonded to a cemented metal carbide substrate 701 at a non-planar interface 130. The substrate 701 at the interface 130 may comprise a tapered surface 702 starting from a cylindrical rim 703 of the substrate 701 and ending at an elevated flatted central region formed in the substrate 701. The cemented metal carbide substrate 701 may be bonded to a front end 705 of a cemented metal carbide bolster 203. The carbide substrate 701 may be brazed to a superhard material 202. Super hard material which may comprise diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, cubic boron nitride, refractory metal bonded diamond, silicon bonded diamond, layered diamond, infiltrated diamond, thermally stable diamond, natural diamond, vapor deposited diamond, physically deposited diamond, diamond impregnated matrix, diamond impregnated carbide, monolithic diamond, polished diamond, course diamond, fine diamond, nonmetal catalyzed diamond, cemented metal carbide, chromium, titanium, aluminum, tungsten, or combinations thereof. The super hard material may be a polycrystalline structure with an average grain size of 10 to 100 microns. The carbide bolster 203 may also comprise at least one cavity 302 formed in its base end 151. The cavity 302 may comprise a section with a uniform diameter 150 which may be capable of receiving a shank in a press-fit arrangement.

The inside surface 160 of the cavity 302 may comprise a section that tapers inward towards a central axis 165 of the tool 101. The cavity 302 may comprise a closed end 166 with a portion 152 of the cavity comprising a widened diameter 161. The cavity 152 may comprise a lip 153, such as shown in FIGS. 1 b-1 c. The cavity 302 may also comprise threads 154, such as shown in FIG. 1 d. The base end 151 may comprise a flat geometry, a concave geometry, a convex geometry or combinations thereof.

FIG. 2 is another cross-sectional diagram of an embodiment of a plurality of tools 101 disposed on a drum 103. The tools 101 may comprise a stem 200 adapted to attach within a groove 201 in the drum 103 such as through a press-fit, or a braze. The impact tools 101 may be spaced less than an inch apart from one another around the drum 103. In some embodiments of the present invention, the bolster actually contact each other. The metal carbide bolster 203 may be in contact with the outer surface 204 of the drum 103.

FIG. 3 is another cross-sectional diagram of an embodiment of a plurality of tools 101 disposed on a drum 103. In this embodiment, the drum 103 comprises a plurality of lugs 301 extending from the outer surface of the drum. The distal end of the lugs fit into the cavities for attachment. The cavities may be press fit, bonded or threaded onto the lugs. The lugs may be welded to the outer surface 204 of the drum. In a preferred embodiment, the tools are closely packed together such that the outer surface of the drum is completely covered or at least outer surfaces exposed surface is greatly minimized compared to traditional milling machines. In such embodiments, the outer surface of the drum is protected from the erosive action of cutting into any formation.

One such advantage to the embodiments shown in FIGS. 2 and 3 is their simplicity. In traditional milling applications blocks or holders are welded onto the drums and picks are secured within them. In the present embodiments, holders are not necessary and the abrasion resistant diamond enhanced carbide bolsters are closer to the surface of the drum, which reduced the bending moment typically experienced in traditional milling. Since only wear resistant parts of the tools are exposed to the abrasive nature of milling, the problems with blocks or holders eroding away are negated.

FIG. 4 is a top perspective diagram of an embodiment of a plurality of impact tools 101. The impact tools 101 may comprise a super hard material 202 and a metal carbide bolster 203. The impact tools 101 may comprise a hexagonal geometry 400. The impact tool may interlock through at least one flat 401 formed in on the side of the bolster. By packing the bolsters close together, exposure to the outer surface of the drum in minimized. Also, by placing the bolsters so close together the bolster may support one another when they engage the formation.

FIG. 5 is another top perspective diagram of an embodiment of a plurality of tools 101. The tools 101 may comprise a square geometry 500 and may interlock through at least one flat 401. FIG. 6 is another top perspective diagram of an embodiment of a plurality of impact tools 101. The impact tools 101 may comprise at least one flat 401 and may interlock through at least one flat 401. The impact tools 101 may also comprise at least one rounded side 601. The impact tools 101 may also be disposed in a “V” formation on a drum (not shown).

FIG. 7 is a cross-sectional diagram of an embodiment of an impact tool disposed on a portion of a drum 103. The carbide bolster 203 may also comprise at least one bore 302 and may be secured against the drum 103 by a ring 700 through a press fit. The ring 700 may be bolted to the drum 103.

FIG. 8 is another cross-sectional diagram of an embodiment of an impact tool 101 disposed on a portion of a drum 103. The drum may comprise a plurality of grooves 201 adapted to receive a middle stem 800 and at least one outer stem 801 of the carbide bolster 203. The outer stem 801 may be shorter in length and width relative to the middle stem 800. The outer stem 801 may comprise a concave geometry, and the middle stem may comprise a rectangular geometry.

FIG. 9 is another cross-sectional diagram of an embodiment of an impact tool 101 disposed on a portion of a drum 103. The carbide bolster 203 may also comprise one middle stem 800 and may be secured against the drum 103 through a press fit. The base end 151 of the of the carbide bolster 203 may comprise a complimentary geometry to that of the drum 103.

FIG. 10 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a portion of a drum 103. The drum 103 may comprise a lug 301 that may be threadedly attached to the drum 103. The lug 301 may also be threadedly attached to the carbide bolster 203 of the tool 101.

FIG. 11 is another cross-sectional diagram of an embodiment of an impact tool 101 disposed on a portion of a drum 103. The drum 103 may comprise a lug 301 that is welded to the outer surface 204 of the drum 103. The carbide bolster 203 may be press-fit to the lug 301.

FIG. 12 is another cross-sectional diagram of an embodiment of an impact tool 101 disposed on a portion of a drum 103. The drum 103 may comprise a lug 301. The lug 301 may be press-fit into the drum 103. The carbide bolster 203 may be press-fit to the lug 301.

FIGS. 13 and 14 are a perspective diagrams of an embodiment of a tool 101. The carbide bolster 203 comprises a bore 302 that may be adapted to receive a bolt 301 through which the bolster may be attached to the drum. In some embodiments, the bolt may be threaded as in FIG. 15 where the bolt is generally arranged parallel to a central axis 165 of the tool. In other embodiments, the bolt may be threaded to the drum such as in the FIG. 14. FIG. 14 also discloses the bolt positioned at an angle with respect to the central axis of the tool. The lug 301 may be inserted through the carbide bolster 203 to create a press-fit. The bore 302 of the carbide bolster 203 may extend through the carbide bolster 203.

FIG. 16 is another cross-sectional diagram of an embodiment of a plurality of tools 101 disposed on a drum 103. The tools 101 may comprise a carbide bolster 203 attached to super hard material 202 and is press fit onto the outer surface of the drum 103. The carbide bolster 203 may comprise a tapered end 1650 opposite the super hard material 202. It is believed that such geometry reduces stress risers in the formation which can result in fragmenting the formation. The drum 103 comprises a central axle 1601 about which it rotates. The central axle may comprise an internal accumulator 1602. The accumulator 1602 may comprise a spring, a filter, and a throw-away filter disc, along with an accumulator vent. The accumulator 1603 may act as a lubrication system 200 comprising oil. The oil lubricates the axle 1651 from the drum 103 as it rotates.

FIG. 17 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a drum 103. The drum 103 may be part of a roller assembly 1600 that may comprise tools 101. The tools 101 may comprise a carbide bolster 203 attached to super hard material 202 and is press fit into the drum 103.

FIG. 18 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a portion of a chain 1850, such as a trenching chain. The chain 1850 may comprise a holder 1800 that may be welded to a plate 1802 of the chain 1850 which moves in the direction of the arrow 1801. The holder 1800 may comprise a reentrant 1803 which may create a compliant region. This may allow the tool to resist more forces. As the tool travels degrading the formation 104 it carries the formation cuttings with it exposing new formation for engagement with adjacent impact tools 101.

FIG. 19 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a degradation machine 1900. The degradation machine 1900 may comprise a plurality of tools 101 adapted to degrade material within a mouth 1901. The machine 1900 may comprise an axle motion which may aid in degrading the material. The machine 1900 may comprise a cam 1902 attached to a wall 1903 of the machine 1900. As the cam 1902 moves it may force the mouth 1901 to close crushing material within the mouth 1901. The machine 1900 may comprise a motor 1904 attached to the cam 1902 and adapted to control the cam 1902.

FIG. 20 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a rotary mill 2000. Material 2001 may enter the rotary mill 2000 where the tool 101 may degrade it. The rotary mill 2000 may comprise at least one arm 2001. The arm 2001 may comprise at least one tool 101 adapted to degrade the material 2001. The rotary device 2000 may also comprise an exit port 2002 where the degraded material may exit.

FIG. 21 is a cross-sectional diagram of an embodiment of a tool 101 disposed on a percussion bit 2100. The percussion bit 2100 may comprise a plurality of lugs 301 adapted to attach to the tool 101. The tool 101 may comprise a carbide bolster 203. The carbide bolster 203 may comprise a cavity 302 adapted to attach to the lugs 301. The percussion bit 2100 may comprise a plurality of tools 101 that may interlock through at least one flat 401.

FIG. 22 is another cross-sectional diagram of an embodiment of a tool 101 disposed on a percussion bit 2100. The percussion bit 2100 may comprise a plurality of recesses adapted to receive the tools 101 through a press-fit. The tool 101 may comprise a stem 200 adapted to interlock with the recesses.

FIG. 23 is another cross-sectional diagram of a plurality of tools 101. The carbide bolsters 203 of the impact tools 101 may comprise a circular geometry 2300, and may be disposed on a target, such as a target 2300 for a vertical shaft mill as shown in FIG. 23.

FIG. 24 and FIG. 25 are cross-sectional diagrams of a plurality of tools 101. The impact tool may be placed on a vibrating arm, such as a rock breaker adapted to degrade material. The impact tool 101 may comprise a cavity 302 that may be press-fit to the vibrating arm.

The tool may be used in a drill bit 2600, as disclosed in FIG. 26. The tool may comprise a bore 302 adapted to be press-fit onto the lugs 301 of the drill bit 2600. In other embodiments, the tools may be incorporated into roller cone bits, water well drill bits, or other types of drill bits.

FIG. 27 is a cross-sectional diagram of a plurality of tools 101 attached to a drum. The bolsters may be retained by a head of the shank, which shanks comprise a distal end attached to a hydraulically movable rod. For convenience when it is desirable to replace a bolster the hydraulically movable rod may extend the shank outward allowing easy access to the bolster so that it may be replaced.

Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention. 

1. An impact resistant tool, comprising; a superhard material bonded to a cemented metal carbide substrate at a non-planar interface; the cemented metal carbide substrate being bonded to a front end of a cemented metal carbide bolster at a planar interface; the bolster comprising a base end opposite of the front end and comprising a substantially conical side wall increasing in diameter from the front end to the base end; and the base end comprising an opening to a cavity formed in the bolster, the opening being coaxial with a central axis of the tool.
 2. The tool of claim 1, wherein a diameter of the front end is less than half of a diameter of the base end.
 3. The tool of claim 1, wherein the base end is substantially flat.
 4. The tool of claim 1, wherein base end comprises a taper generally increasing towards the front end.
 5. The tool of claim 1, wherein the base end is substantially convex or concave.
 6. The tool of claim 1, wherein the opening comprises a smaller diameter than a portion of the cavity.
 7. The tool of claim 1, wherein the opening is comprises a radius, a chamfer, a bevel, a conic, or combinations thereof.
 8. The tool of claim 1, wherein the carbide substrate comprises a diameter larger than the diameter of the front end.
 9. The tool of claim 1, wherein the superhard material is about 75% to 175% of a volume of the metal carbide bolster.
 10. The tool of claim 1, wherein the carbide bolster comprises at least one flat disposed on its outer surface.
 11. The tool of claim 1, wherein the cavity comprises at least one threadform adapted to attach to a threaded shank.
 12. The tool of claim 1, wherein the opening comprises an annular taper generally decreasing from the base end the taper and being intermediate the base end and the cavity.
 13. The tool of claim 1, wherein the opening comprises an annular taper generally increasing from the base end the taper and being intermediate the base end and the cavity.
 14. The tool of claim 13, wherein the taper is between 35 and 55 degrees.
 15. The tool of claim 1, wherein a diameter of the substrate is less than a diameter of the opening.
 16. The tool of claim 1, wherein the superhard material comprises an apex comprising a radius of 0.50 to 0.125 and a thickness greater than 1100 inches.
 17. The tool of claim 16, wherein the superhard material thickness is greater than a third of the diameter of the planar interface.
 18. The tool of claim 1, wherein the cavity comprises a first end with a diameter greater than a diameter of the opening in the base end of the carbide bolster.
 19. The tool of claim 17, wherein the first end of cavity comprises a domed geometry.
 20. The tool of claim 1, wherein the cavity comprises a height greater than or equal to that of the height of the superhard material. 